Method of manufacturing collated T-Nuts

ABSTRACT

A continuous strip of T-Nuts formed on a common strip of metal. Each T-Nut of the strip of T-Nuts is integrally connected to the next adjacent T-Nut by carry tabs. The carry tabs can be frangible themselves or contain a frangible portion. Each T-Nut includes a cylindrical bore therein and a threaded interior. A mechanism feeds and severs the endmost T-Nut in endwise fashion. The mechanism to feed and sever the endmost T-Nut includes a cutting blade positioned vertically below the frangible portion of the carry tab. A shearing ram having a guide positioned axially in line with the cylindrical bore in the endmost T-Nut is adapted to move vertically from an upper to a lower position to engage the cutting blade with the frangible portion and sever the endmost T-Nut.

This application claims priority to and the benefit of copending UnitedStates Provisional Patent Application Ser. No. 61/433,300 filed Jan. 17,2011. United States Provisional Patent Application Ser. No. 61/433,300filed Jan. 17, 2011 is incorporated in its entirety by reference hereto.

FIELD OF INVENTION

The invention is in the field of fasteners.

BACKGROUND OF THE INVENTION

Existing collated fasteners are manufactured and then collated using asecondary process. One process uses a progressive die method to cut theT-Nuts off from the steel or stainless steel strip and then tap thethreads in a secondary process. The secondary process commonly uses glueto hold the fasteners together for later dispensation. Fasteners whichare glued together include staples, nails, screws, clips, etc.

One known method for collating T-Nuts includes adhering the T-Nuts totape and rolling them into a coil during a secondary operation. FIG. 13is a view 1300 illustrating a prior art backing strip 1301 securingindividual T-Nuts 1302 thereto by means of adhesive as illustrated inU.S. Pat. No. 5,214,843. FIG. 13A is a view 1300A illustrating a priorart device illustrated in U.S. Pat. No. 5,214,843 with wires 1304, 1305welded to individual T-Nuts 1302.

Presently known methods of collating T-Nuts using tape have severaldisadvantages. First, T-Nuts can easily become detached or ‘unstuck’from the tape. Factors such as temperature and humidity can have anadverse reaction on the adhesive properties of tape. Second, tapedT-Nuts on a coil do not withstand impact well. Common forces involvedwith activities such as shipping and/or handling can cause T-Nuts todetach. Third, the tape is flexible and the coil of T-Nuts does not havevery rigid structure. Tape coiled T-Nuts must be laid-out and kept flat.If they are moved into a vertical angle they can lose their coiled formand begin to unravel. All current methods of collating T-Nuts involve asecondary process to collate the fasteners.

In the most common manufacture of individual T-Nuts, a band or metalstrip of steel is drawn wherein the barrels of the T-Nuts are formed.Once the barrels of the T-Nuts are formed, the T-Nuts are severed fromthe strip. Threads are then tapped in the barrels of the T-Nuts andprongs may be added if not previously formed in the drawing step.

In a less common manufacture of individual T-Nuts, a band or metal stripof steel is drawn wherein the barrels of a plurality of T-Nuts areformed and then multiple spindles tap the plurality of barrels of T-Nutswhile they are still integral with the metal strip. Thereafter, prongs(pawls) of the are formed on the T-Nuts and the individual T-Nuts aresevered from the band or metal strip.

SUMMARY OF THE INVENTION

The disclosed method of collating T-Nuts does not involve a secondaryprocess. Because the disclosed method taps the T-Nuts while they arestill on and integral with the metal strip a secondary process is notnecessary. Collation of fasteners is used to ease the installationprocess of the fasteners. When fasteners are collated they are correctlyassembled and consistently arranged in a fixed orientation. Formed andcollated T-Nuts arranged in a steel strip are used in conjunction withT-Nut delivery system.

The invention includes a plurality of collated T-Nuts that reside in asteel strip. The collated T-Nuts are installed by automation equipmentthat shears individual T-Nuts from the coil. T-Nuts are commonlyinstalled into, but not limited to, the following materials: wood,particle board, medium-density fiberboard (MDF), plywood, and variousplastics.

Any reasonable thickness, width, and length strip of low carbon steel orstainless steel may be used to form T-Nuts collated by carry tabsbetween the flanges of each T-nut. In other words, the T-Nuts are formedin and from a continuous metal strip. Carry tabs include a frangibleportion which enables severing of the T-Nuts.

The T-Nuts may take many forms. They may have a straight barrel or thebarrel may have a stepped exterior. The barrel may be tapered. Thebarrel may include a counterbore therein and the counterbore may bethreaded or unthreaded. A bore through the T-Nut may be fully threadedcompletely therethrough. Alternatively, the bore through the T-Nut maybe partially threaded therethrough. The barrel length can vary. Threadsmay be any size and fit of imperial or metric standards.

Barrels can have the option of having skives on them. Skives cause theT-Nut to twist upon insertion and help increase retention of the T-Nutin the component. This type of T-Nut is known as a Propell nut. ThePropell T-Nut has various flange sizes and geometries. The flanges mayhave various features such as prongs, holes, and welding bosses of anysize and configuration. Carry tabs are used to connect each T-Nut toanother. Carry tabs are either frangible themselves or include afrangible portion. Size, shape and location of the carry tabs can vary.All T-nut configurations disclosed herein may have various flange sizesand geometries.

These steel or stainless steel coil T-Nuts are manufactured using aprogressive die method. This process starts with a coil of steel orstainless steel being fed into a press containing several stages ofdies. The dies draw the steel or stainless steel at several locationsand form barrels.

After the barrels are formed the steel or stainless steel strip advancesto a station where the barrels are tapped. After the barrels are tappedthe strip is cut to form the flange shape and carry tab. Many differentshapes and configurations of the flanges and carry tabs are disclosedherein.

The next stage of the process is to form flange features such as prongs,holes, or bosses. This stage is typically carried out in conjunctionwith cutting the T-Nut from the strip. Dies also create other featuressuch as prongs (pawls) and apertures in the metal strip. In order tokeep the T-Nuts collated on the coil, the prongs will be formed but thecarry tab will remain intact. Instead of using the carry tab, otherstructure such as a railing or plural rails may be used to hold theT-Nuts together. After this the T-Nuts can be rolled up securely into acoil and the coil is sufficiently rigid so that the coil does notunravel.

Steel or stainless steel coil T-Nuts have advantages over individualdetached T-Nuts. Complete manufacturing is executed in one singleoperation or series of operations. T-Nuts are formed, tapped, and rolledup on a coil without requiring any secondary operations. The time toproduce T-Nuts decreases and production costs are reduced. BecauseT-Nuts are collated on a coil they can be wound up on a reel instead ofbeing packaged in cardboard boxes, which reduces packaging costs. SomeT-Nuts have geometries that typically present feeding issues invibratory bowls and tracks. Collated T-Nuts of the invention simplifythe feeding process by eliminating the need for a vibratory bowl andtrack. T-Nut machines that feed T-Nuts using a vibratory bowl and trackcan experience feeding issues in a dusty/dirty environment.

T-Nut users in woodworking related industries experience problems withsawdust. Sawdust in the atmosphere can settle on the T-Nuts and causejamming in vibratory bowls and tracks. Collated T-Nuts on a steel orstainless steel coil do not require vibratory bowls and tracks,therefore eliminating potential jamming. The collated parts disclosedherein that are fed into automation equipment do not require anelectrical vibratory system to feed parts. Steel or stainless steel coilT-Nuts can be easily fed into automation equipment.

The need for lifting boxes of individual T-Nuts and pouring them into avibratory machine hopper is eliminated by the invention. Multiple steelor stainless steel coils of the T-Nuts rolled up into a coil asdisclosed herein can be stored directly on the machine frame and easilyreloaded as needed. Also, since the T-Nut coils disclosed herein arestable, a larger coil can be loaded onto a pallet reel and fed into aninstallation machine to run even larger quantities of T-Nuts beforehaving to reload.

Installation of steel or stainless steel coil T-Nuts is automated. Toautomate the installation of the steel or stainless steel coil T-Nuts, afeeding system is utilized to advance the T-Nuts. Some slack must beavailable to allow the T-Nuts to advance.

The T-Nuts on the coil, once completely formed, are advanced using apneumatic cylinder(s) to push/pull the T-Nuts. The pneumatic cylinder isfitted with an engaging tool. In one example, the barrels of the T-Nutsmay be engaged by the engaging tool.

When in position a shearing in-body will push the T-Nuts downward overthe blade shearing an individual T-Nut from the strip. Once sheared fromthe strip, the detached T-Nut is free to be advanced further down andinto the pilot hole of the component (substrate).

A method of making a continuous length of integrally connected T-Nuts isdisclosed and claimed. The method includes the steps of: selecting acontinuous length of deformable metal material which is generally flatin configuration and which has first and second side portions and topand bottom portions; introducing the deformable metal materialprogressively into successive die stations which act to successivelyform spaced and generally hollow cylindrical configurations on the uppersurface of the metal material of successively greater diameter and axiallength; moving the generally cylindrical configurations successively toanother station whereat threads are formed on a hollow interior thereof;moving the threaded generally cylindrical configurations progressivelyto a still further station wherein heads are formed for the T-Nuts inthe nature of flanges which define the perimeter of the heads and alsoform carry tabs, the carry tabs are frangible connections or includefrangible connections between adjacent T-Nuts; and, arranging theintegrally connected T-Nuts into a tight helical configuration forshipment or for manufacturing use.

Additionally, the method may include the steps of: feeding thecontinuous length of integrally connected T-Nuts into proximity of itsuse and severing the endmost T-Nut from the length of T-Nuts; and,attaching the severed endmost T-Nut to a substrate, the step ofattaching the severed endmost T-Nut to a substrate includes insertingthe cylindrical configuration thereof into a cylindrical opening in thesubstrate. Still additionally, the method includes the steps of: formingprongs, holes and/or bosses on the flanges.

The apparatus of a continuous length of integrally connected T-Nuts isdisclosed and claimed as well. The apparatus of a continuous length ofintegrally connected T-Nuts, includes: a continuous length of deformablemetal material which is generally flat in configuration; the continuouslength of deformable metal material includes first and second sideportions, a top portion and a bottom portion; a plurality of spaced andgenerally hollow cylindrical configurations extending vertically fromthe top portion of the metal member; the generally hollow cylindricalportions include interior threads therein; wall means on each of theT-Nuts defining a head therefor; the wall means further defines a carrytab intermediate adjacent T-Nuts, and, the carry tab comprises aweakened connection between the adjacent T-Nuts for ease in separatingthe T-Nuts. The apparatus may further include T-Nuts having prongs,holes and/or bosses formed on the head/flange.

Another example of a continuous length of integrally connected T-Nuts,includes: a continuous length of deformable metal material which isgenerally flat in configuration; the continuous length of deformablemetal material includes first and second side portions, a top portionand a bottom portion; a plurality of spaced and generally hollowcylindrical configurations on each of the T-Nuts extending verticallyfrom the top portion of the metal member, the generally hollowcylindrical portions include a bore therethrough with interior threadstherein, and, the generally hollow cylindrical portions of the T-Nutsdefining barrels therefor; wall means on each of the T-Nuts defining ahead or flange therefor; and, the wall means further define a continuousrail interconnecting said T-Nuts.

An apparatus for severing a T-Nut from the end of a strip of T-Nuts isalso disclosed and claimed, and includes: the strip of T-Nuts beingformed on a common strip of metal; each of the T-Nuts of the strip ofT-Nuts being integrally connected together at a frangible portion with anext adjacent T-Nut; each of the T-Nuts includes a cylindrical boretherein; a mechanism to feed and sever the strip of T-Nuts in endwisefashion, the mechanism includes a positioning member, and an endmostT-Nut being in engagement with the positioning member; the mechanism tofeed and sever the strip of T-Nuts in endwise fashion further includes:a cutting blade positioned vertically below the position of thefrangible portion when the endmost T-Nut is in engagement with thepositioning member; and, the mechanism to feed and sever the strip ofT-Nuts includes a shearing ram (shearing inbody) having a guide fingerpositioned axially in line with the cylindrical bore in the endmostT-Nut and adapted to move vertically from an upper to a lower positionto engage the cutting blade with the frangible portion and sever theendmost T-Nut from the strip of T-Nuts. The apparatus for severing aT-Nut from the end of a strip of T-Nuts may further include a guidefinger which resides in the cylindrical bore of the endmost T-Nut tocarry the severed endmost T-Nut to another position separated from thestrip of T-Nuts. Still additionally, the apparatus for severing mayinclude components for inserting the T-Nut into a substrate wherein thesubstrate includes an opening therein.

The guide finger resides in the cylindrical bore of the endmost T-Nut tocarry the severed endmost T-Nut to the opening in the substrate wherethe T-Nut is to reside to perform a support function in later use. Aguide mechanism is located below the end of the strip of T-Nuts andincludes a support wall surface to engage the penultimate T-Nut of thestrip so as to maintain its integrity with the strip until thepenultimate T-Nut is severed from the strip. means for moving theshearing ram vertically between upper and lower positions are alsodisclosed.

Another apparatus for severing a T-Nut from a strip of collated T-Nutsis disclosed. In this apparatus example, a double acting pneumaticcylinder drives a tool which is notched for engagement with the pawl ofthe T-Nuts. The tool is notched such that at least two gripping surfacesengage the pawl. Two pneumatic cylinders may be used to engage the stripof T-Nuts, the first cylinder operates from the first side of anescapement and the second cylinder operates from the second side of theescapement. The escapement is the device which feeds and severs theT-Nuts and enables the insertion into a substrate for use. Theescapement includes a generally rectangularly shaped T-Nut passagewaywhich enables T-Nuts to be pushed therethrough by one or more pawlengaging tools driven by pneumatic cylinders. The pneumatic cylindersindex the collated strips of T-Nuts into a position where they can besubsequently severed under the force of a shearing inbody which ispiston driven. The escapement includes a pivotal bottom arm which allowsthe strip of T-Nuts to be forced downwardly where a frangible orseverable portion of the T-Nut assembly is brought into engagement witha shearing blade. The shearing inbody includes a guide (stud) whichenters the bore of the T-Nut to be severed so as to ensure separation ofthe T-Nut from the collated strip of T-Nuts when the frangible portion(weakened portion) is brought into engagement with the shearing blade ofthe escapement. The strip of T-Nuts, during the feeding operation (theinstallation operation of the T-Nuts into a substrate), resides in thepassageway of the escapement and as the T-Nuts are forced downwardly tobe severed, the pivotal bottom arm rotates downwardly approximately theheight of one T-Nut. The height of the T-Nut is measured from the top ofthe flange to the end of the barrel of the T-Nut. As the T-Nut to besevered is forced down such that its frangible portion (weakenedportion) engages the shearing blade of the escapement, the strip ofT-Nuts is rotated slightly downwardly. Therefore, there must be someslack in the strip of T-Nuts being fed into the escapement. The end ofthe coil closest to where the T-Nuts are to be installed must allow forflexibility in the vertical direction. The reason for this is to allowthe T-Nuts to advance above the shearing blade.

The another apparatus for severing a T-Nut from the end of a strip ofT-Nuts uses a common strip of metal. The common strip of metal includesa plurality of T-Nuts thereon. Each of the plurality of T-Nuts of thecommon strip of T-Nuts includes a flange integrally connected by afrangible portion with a flange of a next adjacent T-Nut. The pluralityof T-Nuts of the common strip includes an endmost T-Nut. The endmostT-Nut is severed from the plurality of T-Nuts of the common strip. Eachof the T-Nuts includes a bore therein and a pair of pawls. An escapementincludes a T-Nut passageway. The T-Nut passageway includes a first sidemember, a second side member, an upper member and a pivotable bottomplate. The upper member is affixed to the first and second side members.The hinged bottom portion rotates between first and second positions.The escapement further includes a chamber for severing the endmostT-Nut. A gripping tool is affixed to a double acting piston. Theescapement severs the endmost T-Nut of the plurality of T-Nuts of thecommon strip in endwise fashion. The escapement includes an opening andthe gripping tool resides in the opening of the escapement positioned toalternately engage and disengage one pawl of the pair of pawls of one ofthe T-Nuts. The double acting piston (also sometimes referred to hereinas a shearing inbody) forcefully moves in a first direction urging thegripping tool into engagement with the one pawl of the pair of pawls ofone of the T-Nuts urging the endmost T-Nut into the chamber. The doublepiston and the gripping tool affixed thereto retracting, in a seconddirection, away from and out of engagement with the one pawl of the pairof pawls of one of the T-Nuts of the plurality of T-Nuts of the commonstrip of T-Nuts. The escapement further includes a cutting bladepositioned vertically below the frangible portion of the endmost T-Nutwhen the endmost T-Nut is in the chamber. The shearing piston resides inthe chamber and the shearing piston is movable between a first upperposition and a second lower position. The shearing piston includes aguide for interengagement with the bore of the endmost T-Nut. An elasticband member operates between the fixed upper portion of the escapementand the hinged bottom portion of the escapement. As the piston movesfrom the first upper position to the second lower position, the guide ofthe shearing piston engages the bore of the endmost T-Nut. The pistonengages the flange of the endmost T-Nut, and the plurality of T-Nuts ofthe common strip rotate the hinged bottom portion between first andsecond positions. The frangible portion of the endmost T-Nut is loweredto, and brought into engagement with, the cutting surface of the cuttingblade severing the endmost T-Nut from the plurality of T-Nuts of thecommon strip.

The method of inserting a T-Nut from a common strip of metal including aplurality of T-Nuts into an opening in a substrate, wherein each of theT-Nuts being integrally connected together by a frangible portion(weakened portion) thereof intermediate adjacent T-Nuts and each of theT-Nuts includes a cylindrical portion, includes the steps of: feedingthe strip of T-Nuts in endwise fashion to a severing position; cuttingthe endmost T-Nut at the frangible portion (weakened portion) to severethe endmost T-Nut from the common strip of metal; carrying the severedT-Nut to and inserting the cylindrical portion of the severed T-Nut intothe opening in the substrate; and, supporting the end of the strip ofthe T-Nuts adjacent the severed endmost T-Nut being severed maintainingintegrity of the T-Nuts adjacent the strip until they are in position tobe severed.

It is an object of the invention to provide a coiled roll of T-Nutswhich is stable and secure for feeding the T-Nuts into a machine whichsevers the T-Nuts and places them securely in a substrate.

It is an object of the invention to provide a strip of collated T-Nutshaving a flexible connection between each T-Nut enabling the T-Nuts tobe rolled up in a coil.

It is an object of the invention to provide a coiled roll of T-Nutswherein each of the T-Nuts is secured to the next adjacent T-Nut by afrangible portion of the coiled roll of T-Nuts.

It is an object of the present invention to provide a coiled roll ofT-Nuts wherein each of the T-Nuts is secured to the next adjacent T-Nutby carry tabs joined together by a frangible (weakened) portion whichcan later be severed in the installation or separation of the T-Nuts.

It is an object of the invention to include carry tabs between adjacentT-Nuts which are either frangible or include frangible portions thereof.

It is an object of the invention to provide a plurality of T-Nuts formedon and of a metal strip and to provide a frangible portion betweenadjacent spaced apart T-Nuts.

It is an object of the invention to provide T-Nuts formed on and of ametal strip and to provide various flanges, holes and prongs as featuresof the T-Nuts.

It is an object of the invention to form T-Nuts on and of a metal stripsuch that the T-Nuts may be reliably separated and installed in a woodensubstrate.

It is an object of the invention to secure T-Nuts on and of a metalstrip through use of one or more rails.

It is an object of the invention to provide an escapement and a chamberassociated therewith which feed and severs the endmost T-Nut from acontinuous strip of T-Nuts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1, 1A and 1B schematically illustrate a die press at a first diestation in three successive positions in operating on a strip of metalin performing the method of the present invention.

FIG. 1C is a schematic isometric illustration of the end of the strip ofmetal as it leaves the press illustrated in FIG. 1B.

FIG. 1D schematically illustrates a die press at a second die station asoperating on the strip of metal after it has left the position of FIG.1B in the condition of FIG. 1C.

FIG. 1E is a schematic isometric illustration of the end of the strip ofmetal as operated on in the press of FIG. 1D.

FIG. 1F schematically illustrates a die press at a third die station asoperating on the strip of metal after it has left the position of FIG.1D in the condition of FIG. 1E.

FIG. 1G is a schematic isometric illustration of the end of the strip ofmetal as operated on in the press of FIG. 1F.

FIG. 1H schematically illustrates a die press at a fourth die station asoperating on the strip of metal after it has left the position of FIG.1F in the condition of FIG. 1G.

FIG. 1I is a schematic isometric illustration of the end of the strip ofmetal as operated on in the press of FIG. 1H.

FIGS. 2, 2A and 2B schematically illustrate a fifth die station at whichthe cylindrical members produced at the previous stations are tapped andprovided with threads.

FIG. 2C is a schematic isometric illustration of the end of the strip ofmetal as operated on at the fifth die station of FIG. 2B.

FIGS. 3, 3A and 3B schematically illustrate a sixth station at which thestrip of metal between the formed cylindrical members is die cut toproduce the heads on the T-Nuts and produce various flange features suchas attachment prongs as shown in FIG. 3B.

FIG. 3C is a schematic isometric illustration of the end of the strip ofmetal as operated on at the sixth die station of FIG. 3B.

FIG. 4 is an isometric illustration similar to FIG. 3B showing aslightly longer length of the connected and formed T-Nuts and slightlyenlarged for detail.

FIG. 4A is an enlarged portion of FIG. 4 illustrating the connectionbetween adjacent T-Nuts and the location at which they will be severedat about their ultimate location of use.

FIG. 4B is a plan view of FIG. 4.

FIG. 4C is an elevational view of FIG. 4B.

FIG. 4D is an end view of FIG. 4C.

FIG. 4E is an enlargement of the side portion of FIG. 4C.

FIG. 5 is a schematic view illustrating the length of integrallyconnected T-Nuts as shown in FIGS. 4 through 4D as wound into a helicalconfiguration for ease in shipping and/or manufacturing.

FIG. 5A is a schematic view of the T-Nuts shown in FIG. 5 in connectionwith one example of an apparatus to sever the endmost T-Nut from itsstrip and in position to be installed in a substrate.

FIG. 5B is a schematic view of the apparatus of FIG. 5A severing theendmost T-Nut from its strip and placing it in an aperture in asubstrate.

FIG. 5C is a schematic view of the apparatus of FIG. 5B moved back inposition to install another T-Nut from the end of the strip into anotheraperture in a substrate.

FIG. 5D is a schematic side view of a strip of collated T-Nuts incombination with another example of an apparatus (an escapement) tosever the endmost T-Nut from its strip.

FIG. 5E is a schematic top view of a strip of collated T-Nuts incombination with the another example of an apparatus (an escapement) tosever the endmost T-Nut from its strip.

FIG. 5F is a schematic cross-sectional view of a strip of collatedT-Nuts in combination with the another example of an apparatus (anescapement) to sever the endmost T-Nut from its strip taken along thelines 5F-5F of FIG. 5D illustrating the piston (shearing inbody) and thetool for advancing the strip, and, illustrating the endmost T-Nut in thechamber for separation from the strip.

FIG. 5G is a schematic cross-sectional view of a strip of collatedT-Nuts in combination with the another example of an apparatus (anescapement) to sever the endmost T-Nut from its strip taken along thelines of 5G-5G of FIG. 5E illustrating the endmost T-Nut in the chamberfor separation from the strip and the shearing inbody (piston) and guidealigned with the endmost T-Nut.

FIG. 5H is a schematic cross-sectional view of a strip of collatedT-Nuts in combination with the another example of an apparatus (anescapement) to sever the endmost T-Nut from its strip illustrating thehinged bottom plate of the escapement rotated downwardly enabling thefrangible connection of the endmost T-Nut in the chamber for separationfrom the strip.

FIG. 5I is a schematic cross-sectional view of a strip of collatedT-Nuts in combination with the another example of an apparatus (anescapement) to sever the endmost T-Nut from its strip illustrating thehinged bottom plate of the escapement returned to its home positionsupporting the strip of collated T-Nuts.

FIG. 5J is a schematic cross-sectional view of a strip of collatedT-Nuts in combination with the another example of an apparatus (anescapement) to sever the endmost T-Nut from its strip illustrating theshearing inbody pushing and inserting the endmost T-Nut into asubstrate.

FIG. 5K is a schematic side view of a coiled roll of T-Nuts wound aroundcore with the barrels oriented radially outwardly.

FIG. 5L is similar to FIG. 5E with the exception being that two pistonsare illustrated for urging the T-Nuts into the chamber for insertionthereafter into a substrate.

FIGS. 6, 6A, 6B and 6C are views of another configuration of T-Nuts madein accordance with the present invention.

FIG. 6D is an enlargement of the frangible portion of FIG. 6 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIGS. 7, 7A, 7B and 7C are views of a further configuration of T-Nutsmade in accordance with the present invention.

FIG. 7D is an enlargement of the frangible portion of FIG. 7 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIGS. 8, 8A, 8B and 8C are views of a still further configuration ofT-Nuts made in accordance with the present invention.

FIG. 8D is an enlargement of the frangible portion of FIG. 8 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIGS. 9, 9A, 9B and 9C are views of yet another configuration of T-Nutsmade in accordance with the present invention.

FIG. 9D is an enlargement of the frangible portion of FIG. 9 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIGS. 10, 10A, 10B and 10C are views of an additional configuration ofT-Nuts made in accordance with the present invention.

FIG. 10D is an enlargement of the frangible portion of FIG. 10 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIGS. 11, 11A, 11B and 11C are views of an additional configuration ofT-Nuts made in accordance with the present invention.

FIG. 11D is an enlargement of the frangible portion of FIG. 11 whichillustrates a slot in the upper portion of the frangible portion andvertical slots on both sides of the frangible portion.

FIG. 12 is a block diagram of the processing of the metal strip.

FIG. 13 illustrates a prior art backing strip securing individual T-Nutsthereto by means of adhesive as illustrated in U.S. Pat. No. 5,214,843.

FIG. 13A illustrates a prior art device illustrated in U.S. Pat. No.5,214,843 with wires welded to individual T-Nuts.

FIG. 14 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel has afirst diameter having a first circumference and a second diameter havinga second circumference.

FIG. 14A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 14 illustrating the frangible connection between adjacentT-Nuts.

FIG. 14B is a plan view of FIG. 14.

FIG. 14C is a cross-sectional view of FIG. 14B taken along the lines14C-14C illustrating interior threads in the first diameter having afirst circumference.

FIG. 14D is an end view of FIG. 14B taken along the lines 14D-14D.

FIG. 14E is a plan view similar to FIG. 14B with a frangible connectionhaving a slight underside indentation.

FIG. 14F is an enlargement of a portion of FIG. 14E illustrating thefrangible connection having a slight indentation.

FIG. 15 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel has afirst diameter having a first circumference and a second diameter havinga second circumference similar to FIG. 14, except with interior threadscompletely through the barrel.

FIG. 15A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 15 illustrating the frangible connection between adjacentT-Nuts.

FIG. 15B is a plan view of FIG. 15.

FIG. 15C is a cross-sectional view of FIG. 15B taken along the lines15C-15C illustrating a fully threaded barrel.

FIG. 15D is an end view of FIG. 15B taken along the lines 15D-15D.

FIG. 16 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel has afirst diameter having a first circumference and a second diameter havinga second circumference similar to FIG. 14, except with interior threadsresiding in the portion of the barrel having a second diameter having asecond circumference.

FIG. 16A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 16 illustrating the frangible connection between adjacentT-Nuts.

FIG. 16B is a plan view of FIG. 16.

FIG. 16C is a cross-sectional view of FIG. 16B taken along the lines16C-16C illustrating interior threads in the second diameter having asecond circumference.

FIG. 16D is an end view of FIG. 16B taken along the lines 16D-16D.

FIG. 17 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel iscylindrically shaped with interior threads in the upper portion of thebore of the cylindrically shaped barrel.

FIG. 17A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 17 illustrating the frangible connection between adjacentT-Nuts.

FIG. 17B is a plan view of FIG. 17.

FIG. 17C is a cross-sectional view of FIG. 17B taken along the lines17C-17C illustrating interior threads in the upper portion of the bore.

FIG. 17D is an end view of FIG. 17B taken along the lines 17D-17D.

FIG. 18 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel iscylindrically shaped with interior threads completely through the boreof the cylindrically shaped barrel.

FIG. 18A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 18 illustrating the frangible connection between adjacentT-Nuts.

FIG. 18B is a plan view of FIG. 18.

FIG. 18C is a cross-sectional view of FIG. 18B taken along the lines18C-18C illustrating interior threads through the entire bore of thecylindrically shaped barrel.

FIG. 18D is an end view of FIG. 18B taken along the lines 18D-18D.

FIG. 19 is an isometric illustration of a length of the strip of anotherexample of collated T-Nuts slightly enlarged wherein the barrel iscylindrically shaped with interior threads in the lower portion of thebore of the cylindrically shaped barrel.

FIG. 19A is a slightly enlarged top schematic view of the collatedT-Nuts of FIG. 19 illustrating the frangible connection between adjacentT-Nuts.

FIG. 19B is a plan view of FIG. 19.

FIG. 19C is a cross-sectional view of FIG. 19B taken along the lines19C-19C illustrating interior threads in the lower portion of the bore.

FIG. 19D is an end view of FIG. 19B taken along the lines 19D-19D.

The invention will be best understood when reference is made to thedescription of the invention and to the claims which follow hereinbelow.

DESCRIPTION OF THE INVENTION

Reference may be had to FIG. 4 for a quick understanding of thecontinuous strip of collated T-Nuts of the invention. The continuousstrip comprises T-Nuts integrally connected together and spaced apartfor later dispensation in a substrate. The integrally connected T-Nutsare formed on and from a continuous steel strip 10. The strip shown inFIG. 4 has been identified by the reference numeral 33. Put another way,reference numeral 33 identifies one example of the completed product,namely, a strip of collated T-Nuts with flanges and parts linkedtogether by carry tabs and frangible portions. As stated previously, thecarry tabs may be frangible or portions of the carry tabs may befrangible. The strip of deformable metal material 10 (FIG. 1) has firstand second side portions 12, 13 and top and bottom portions 15, 16 andis fed into a first die station 18 (FIGS. 1, 1A, 1B) which is housed inpress 34. FIGS. 1, 1A and 1B illustrate a die press at a first diestation 18 in three successive positions 100, 100A, 100B in operating ona strip of deformable metal material 10 in performing the method of thepresent invention. FIG. 1C is an isometric illustration 100C of the endof the strip of metal 10 as it leaves the press 34 illustrated in FIG.1B.

The strip of metal 10 may be made from many different steels of varyingwidths and thicknesses. Low carbon steels and 300 series stainlesssteels are examples. C1006-1008 steel, 304 stainless steel, or any oftheir international equivalents may be used. The thicknesses of thesteels varies, but most will be in the range of 0.039″ [1.0 mm] to0.063″ [1.6 mm] thick. The width of the T-nuts also varies, but commonlythe widths are in the range of 0.625″ [15.9 mm] to 1.000″ [25.4 mm]wide. Other widths and thicknesses are specifically contemplated.

The press includes upper and lower platens 35, 36 which are normallyurged apart by springs 37, 38 and which press has upper and lower rams39, 40 which may be hydraulically actuated to bring the platens togetherto form the steel strip into the configurations described hereafter.

The die station 18 includes die members 18A which act on the metalmaterial 10 when the platens 35, 36 are brought together as illustratedin FIG. 1A and when they are separated as illustrated in FIG. 1B. InFIG. 1B the initial shapes of the cylindrical configurations of theT-Nuts has been formed and they have been identified by the referencenumeral 22. Die members 19A at a second die station 19 serve to furtherenlarge the cylindrical members to the condition 22A shown in FIG. 1D.FIG. 1D is a view 100D illustrating a die press at a second die station19 as operating on the strip of metal 10 after it has left the positionof FIG. 1B in the condition of FIG. 1C. FIG. 1E is an isometricillustration 100E of the end of the strip of metal 10 as operated on inthe press of FIG. 1D.

Next the strip of deformable metal material is moved to a third diestation 20 (FIG. 1F) where die members 20A act further on thecylindrical members to enlarge them further to the condition of 20B seenin FIGS. 1F and 1G. FIG. 1F is a view 100F illustrating a die press at athird die station 20 as operating on the strip of metal 10 after it hasleft the position of FIG. 1D in the condition of FIG. 1E. FIG. 1G is anisometric illustration 100G of the end of the strip of metal 10 asoperated on in the press of FIG. 1F. FIG. 1G illustrates that thecylindrical members are becoming longer and diametrically larger.

The metal strip is next moved to a fourth die station 21 where dies 21Aproduce the final cylindrical shape 22C shown in FIGS. 1H and 1I. FIG.1H is a view 100H illustrating a die press at a fourth die station 21 asoperating on the strip of metal 10 after it has left the position ofFIG. 1F in the condition of FIG. 1G. FIG. 1I is an isometricillustration 1001 of the end of the strip of metal as operated on in thepress of FIG. 1H.

The strip of metal with the linearly spaced cylindrical members 22C isnext moved to a fifth station 24 where taps 28 are provided and aremoved axially into members 22C to provide internal threads 44 thereonand produce the internally threaded members now identified at 42. FIGS.2, 2A and 2B illustrate 200, 200A, 200B, a fifth die station 24 at whichthe cylindrical members 42 produced at the previous stations are tappedand provided with threads. FIGS. 2, 2A and 2B illustrate successivesteps 200, 200A, 200B in tapping the internal threads within thecylindrical members 42. FIG. 2C is an isometric illustration 200C of theend of the strip of metal as operated on at the fifth die station ofFIG. 2B.

The next step in the process of producing the collated T-Nutconstruction of the invention is to die cut the flanged headconstruction of the nut and to produce any desired flange or attachmentfeature. To this end, the metal strip 10 is moved to a sixth station 25where a die 25A, not shown in any specific configuration, but which hasa pattern corresponding to the shape produced thereby, produces strip 33of the finished and integrally connected T-Nuts 33 referred to above inthis description. The die 25A takes the necessary configuration toproduce T-Nuts as illustrated in FIGS. 4, 6, 7, 8, 9, 10, 11, 14, 15,16, 17, 18, and 19. Other configurations not shown in FIGS. 4, 6, 7, 8,9, 10, 11, 14, 15, 16, 17, 18, and 19 are specifically contemplated.FIGS. 3, 3A and 3B are view 300, 300A, 300B, respectively, illustratinga sixth station 25 at which the strip of metal 10 between the formedcylindrical members is die cut to produce the flanged heads on theT-Nuts and produce various flange features such as attachment prongs asshown in FIGS. 3B and 3C. FIG. 3C is an isometric illustration 300C ofthe end of the strip of metal 10 as operated on at the sixth die stationof FIG. 3B.

The finished and completed strip 33 includes the collated T-Nuts whichcomprise the spaced cylindrically shaped members 42 which are internallythreaded at 44 and which have flanged heads 50 with attachment prongs 46formed at a position which can be said to be at the first and secondside portions 12, 13 of the metal strip 10. A frangible portion 48 isformed in the die cutting operation of FIGS. 3, 3A and 3B and serves todefine the interconnection between adjacent T-Nuts. A carry tab fromeach adjacent T-Nut of the strip is connected to the frangible portion.The frangible portion is of such thickness and strength to keep theplurality of T-Nuts connected in shipment and when otherwise being movedand handled. The frangible portion is also of a thickness and strengththat it can conveniently be severed from the strip enabling installationin its ultimate place of use, for instance, in an opening in asubstrate.

FIG. 4 is an isometric illustration 400 similar to FIG. 3B showing aslightly longer length of the connected and formed T-Nuts and which isslightly enlarged for detail. FIG. 4A is an enlarged portion 400A ofFIG. 4 illustrating the carry tabs and frangible portion 48 thereofbetween adjacent T-Nuts. Frangible portion 48 is the location at whichthe adjacent T-Nuts will be severed. Carry tabs 92A, 92B are illustratedon either side of frangible portion 48. FIG. 4B is a plan view 400B ofFIG. 4. FIG. 4C is an elevational view 400C of FIG. 4B. FIG. 4D is anend view 400D of FIG. 4C. Arrow 93 in FIG. 4 indicates theinterconnection between adjacent T-Nuts. A frangible portion 48 incombination with tabs 92A, 92B join adjacent T-Nuts together. Sometimesthe tabs 92A, 92B are referred to herein as carry tabs. Carry tabs 92A,92B and the frangible portion 48 thereof are used to join the T-Nutstogether and enable further processing of the T-Nuts and installation ofthe T-Nuts into a substrate. FIG. 4A is an enlargement 400A of thefrangible portion 48 which illustrates slot 90 in the upper portion ofthe frangible portion and vertical slots 91, 91 on both sides of thefrangible portion. FIG. 4E is an enlargement 400E of the side portion ofFIG. 4C illustrating vertical slot 91 in the frangible portion 48.

FIG. 5 is a view 500 illustrating a length of integrally connectedT-Nuts as shown in FIGS. 4 through 4E as wound into a helicalconfiguration for ease in shipping and/or handling for furtherprocessing. FIG. 5A is a view 500A of the T-Nuts shown in FIG. 5 inconnection with one example of an apparatus to sever the endmost T-Nutfrom completed strip 33 and position the endmost T-Nut for installationin a substrate. FIG. 5B is a view 500B of the apparatus of FIG. 5Asevering the endmost T-Nut from its strip 33 and placing it in anaperture in a substrate. FIG. 5C is a view 500C of the apparatus of FIG.5B moved back in position to install another T-Nut from the end of thestrip into another aperture in a substrate.

Referring again to FIG. 5, the strip 33 of T-Nuts is wound in a helicalpattern for shipment or to be placed on a mandrel in a manufacturingoperation of placing the individual T-Nuts into a substrate to receiveand hold a support screw in a fastener application. The frangibleportion 48 enables the coil to be wound more readily because thefrangible portion is a weakened portion. Because the frangible portion48 is narrow in cross-section it is easily bent enabling a long strip 33of T-Nuts to be wound in a coil. The frangible portion 48 need notinclude a slot or slit therein. See FIGS. 14, 15, 16, 17, 18 and 19.Coils having approximately 1100 T-Nuts can be wound and are stable.

FIGS. 5A, 5B and 5C are views 500A, 500B, 500C, respectively,illustrating the apparatus and method of use of the completed strip 33of helically wound T-Nuts shown in FIG. 5. The apparatus includes ashearing station 52 and has a positioning abutment 53 adapted to engageand position the end of the strip 33 which is driven into the positionof FIG. 5A by an advancement finger 54 which pivots on a torsion springdriven by a pneumatic cylinder, not shown. A shearing blade assembly 55is located below the end of the strip 33 and includes a blade 56, andguide cylinders 57, each of which are biased upwardly by springs 58.

A shearing ram 59 is positioned above the end of strip 33 and has aguide finger 60 which is adapted to fit into the opening in the endmostT-Nut. The two T-Nuts next adjacent the endmost T-Nut are adapted to fitinto and be supported by the guide cylinders 57 during a shearingoperation by the downward movement of ram 59 causing the tab 48 of theendmost T-Nut to engage blade 56 and to be severed from the strip. Thefinger 60 carries the severed T-Nut to an opening 61 in a substrate 89where it is to reside. The ram 59 is then returned to the position ofFIG. 5C preparatory to another cycle. Reference numeral 81 signifies thehorizontal movement of the continuous strip of T-Nuts, reference numeral82 indicates the vertical movement of the continuous strip of T-Nuts,and reference numeral 83 indicates the horizontal movement of thesubstrate 89.

Another apparatus for severing a T-Nut from the end of a strip of T-Nutsis disclosed in FIGS. 5D to 5J, and 5L. FIG. 5D is a schematic side view500D of a strip 74 of collated T-Nuts in combination with anotherexample of an apparatus 599 (an escapement) to sever the endmost T-Nut74E from its strip 74. See FIG. 5K which is a schematic side view 500Kof a coiled roll 598 of T-Nuts wound around core 597 with the barrels142 oriented radially outwardly. The continuous strip 74 of T-Nuts iseasily wound as the frangible portions 148 between carry tabs andflanges 150, 150 of adjacent T-Nuts is bendable without severing theadjacent T-Nuts from each other. Each T-Nut includes a barrel 142, aplurality of prongs 169A, 169B, 169C and 169D, a flange 150, carry tabs194A, 194B, and a frangible portion 148 connected to adjacent T-Nuts.

A common strip 74 of metal includes a plurality of T-Nuts thereon asillustrated in FIG. 5K. The strip 74 is fed into an escapement 599.Referring to FIGS. 5D, 5E, 5F, 5G, 5H and 51, strip 74 includes aplurality of T-Nuts in escapement 599. Escapement 599 includes a chamber599A where the endmost T-Nut 74E is severed.

Referring to FIG. 5D, shearing ram inbody 501 shears the endmost T-nut74E from the strip 74 of integrally connected T-Nuts. Guide 501G ofinbody 501 is illustrated in section in FIGS. 5E and 5G. Guide 501Gengages the bore of the endmost T-Nut 74E in the severing process.

FIG. 5E is a schematic top view 500E of the strip 74 of collated T-Nutsin combination with the another example of an apparatus 599 (anescapement) to sever the endmost T-Nut 74E from its strip.

FIG. 5G is a schematic cross-sectional view 500G of the strip 74 ofcollated T-Nuts in combination with the another example of an apparatus599 (an escapement) to sever the endmost T-Nut 74E from its strip 74taken along the lines of 5G-5G of FIG. 5E illustrating the endmost T-Nut74E in the chamber 599A for separation from the strip 74 and theshearing inbody 501 and guide 501G aligned with the endmost T-Nut 74E.

FIG. 5F is a schematic cross-sectional view 500F of the strip 74 ofcollated T-Nuts in combination with the another example of an apparatus599 (an escapement) to sever the endmost T-Nut 74E from its strip takenalong the lines 5F-5F of FIG. 5D illustrating the piston 530 and thegripping tool 530T for advancing the strip 74, and, illustrating theendmost T-Nut 74E in the chamber 599A for separation from the strip 74.FIG. 5L is similar to FIG. 5E with the addition of a second piston 530Awhich resides in slot 532. See FIG. 5D for an illustration of open slot531 in side wall 503 and open slot 532 in side wall 503A. Open slot inside wall 503 permits access of gripping tool 530T to pawls/prongs ofT-Nuts on strip 74. Open slot in side wall 503A permits access ofgripping tool 530T to pawls/prongs of T-Nuts on strip 74. Guidingsurfaces 531S, 532S direct gripping tools 530T, 530T along side walls503, 503A and into engagement with the prongs/pawls of the T-Nuts.Referring to FIG. 5F, surfaces 540R, 541R of tool 530T engagecorresponding surfaces 540, 541 of the prong/pawl.

Gripping tool 530T resides in openings 531, 532 of the escapement and ispositioned to alternately engage and disengage one pawl of the pair ofpawls of one of the T-Nuts. Double acting piston 530 forcefully moves ina first direction urging the gripping tool 530T into engagement with onepawl of the pair of pawls of one of the T-Nuts urging the endmost T-Nut74E into the chamber. See FIG. 5F. Double acting piston and the grippingtool affixed thereto retracts, in a second direction, away from and outof engagement with the one pawl of the pair of pawls of one of theT-Nuts of the plurality of T-Nuts of the common strip of T-Nuts.

Referring to FIGS. 5D and 5E, rod 530R of tool 530T is illustrated. Whenpiston 530 is extended in the first direction toward the strip 74 ofT-Nuts for engagement therewith, rod 530R is in sliding engagement withside wall 503 and pivots the arm clockwise when viewing FIGS. 5E and 5Fagainst the force, F, applied by a spring. The spring operates betweenthe piston 530 and a point affixed to the frame of which the escapementis a part thereof. Piston 530 pivots about shaft 530P and nut 530N isaffixed to the shaft and rotates therewith. Pressure ports 530P, 530Qare illustrated in FIG. 5E and supply pressure to the double actingpiston 530. Double acting piston 530 extends the gripping tool 530T in afirst direction toward the strip 74 of T-Nuts and into engagementtherewith. Double acting piston 530 also retracts the gripping tool 530Taway from the strip 74 of T-Nuts. Force, F, of the spring or otherbiasing member such as an elastic band, ensures the proper orientationof the gripping tool 530T. Gripping tool 530T is affixed to a shaft ofthe piston and is moveable therewith.

Referring to FIGS. 5D and 5E, upper portion 502 and side wall 503 of theescapement is illustrated. FIG. 5F illustrates side wall 503A. Sidewalls 503, 503A are affixed to upper portion 502 of escapement 599.Bolts 502N illustrated in FIG. 5E affix the upper portion 502 of theescapement 599 to side walls 503, 503A. Hinged bottom of escapement 550is illustrated in FIGS. 5F and 5G and fits substantially within walls503, 503A. Hinged bottom 550 rotates about pivot 504P shown in FIG. 5G.Nuts 504, 504A shown in FIGS. 5D and 5F secure the pivot 504P to sidewalls 503, 503A. Referring to FIG. 5D, lower portion 507 of the hingedbottom 550 is illustrated. Lower pin 506 is affixed to the hinged bottom550. Upper pin 505 is affixed to upper portion 502 of the escapement.Elastic band 531 operates between upper pin 505 and lower pin 506 andserves to restrain the rotation of the hinged bottom unless the strip 74of T-Nuts is under the force of shearing inbody 501 as illustrated inFIG. 5H.

FIG. 5H is a schematic cross-sectional view 500H of a strip 74 ofcollated T-Nuts in combination with the another example of an apparatus599 (an escapement) to sever the endmost T-Nut 74E from its stripillustrating the hinged bottom plate 550 of the escapement 599 rotateddownwardly enabling the frangible connection 148 of the endmost T-Nut74E in the chamber 599A to be separated from the strip 74. Chamber 599Aincludes plates 510, 511, 511A, 512 which form a square incross-section. Other geometric chamber forms could be used, for example,rectangular, circular, etc. and other geometric shearing inbody formscould be used. The square shape has been found to sever the frangibleconnections 148 well.

FIG. 5I is a schematic cross-sectional view 500I of a strip 74 ofcollated T-Nuts in combination with the another example of an apparatus599 (an escapement) to sever the endmost T-Nut 74E from its stripillustrating the hinged bottom plate 550 of the escapement 599 returnedto its home position (first position) supporting the strip 74 ofcollated T-Nuts. FIG. 5J is a schematic cross-sectional view 500J of astrip 74 of collated T-Nuts in combination with another example of anapparatus 599 (an escapement) to sever the endmost T-Nut 74E from itsstrip 74 illustrating the shearing inbody 501 pushing and inserting theendmost T-Nut 74E into an opening 558 substrate 560. After the endmostT-Nut 74E has been fully inserted in the opening 558, the shearinginbody 501 is retracted to its home position (upper position) asillustrated in FIG. 5G above the strip 74 of T-Nuts. Shearing inbody501, when moved from its lower position to its upper position, is thenready for another cycle of shearing and inserting the endmost T-Nut. Theshearing inbody 501 is driven by a piston (not shown) and the action ofthe shearing inbody and the piston 530 is coordinated to properlydeliver the endmost T-Nut to the chamber 599A at the appropriate time.

Referring to FIGS. 5D, 5F, 5G, 5H, 5I and 5J, cutting blade 508 isillustrated. In FIG. 5F, endmost T-Nut 74E is illustrated in chamber599A. Frangible portion 148 connecting the endmost T-Nut with the nextadjacent T-Nut is positioned in alignment with cutting surface 508C ofcutting blade 508. In FIG. 5G, frangible portion 148 is aligned withcutting surface 508C of the cutting blade 508. Cutting blade 508 isaffixed to plate 510 by bolt 509. In FIG. 5H, shearing inbody 501 isillustrated in engagement with the endmost T-Nut 74E pushing itdownwardly and, simultaneously, shearing inbody pushes the adjacentT-Nut and the next several T-nuts downwardly against the bottom plate550 of the escapement. Frangible portions 148 of the T-Nuts do not breakapart or sever as viewed in FIG. 5H. Rather, the frangible portions aresufficiently strong so as to not separate when the shearing inbody(piston) 501 engages the endmost T-Nut 74E and pushes it down to thecutting surface 508C of the cutting blade 508. The force applied to thebottom plate 550 is resisted by the elastic band 513 illustrated in FIG.5D. As bottom plate 550 rotates clockwise about pivot 504P, the elasticband stretches due to the force being applied to the strip 74 of T-Nutsby the shearing inbody 501. Once the frangible interconnection is brokenor severed, then the strip 74 of T-Nuts and the bottom plate 550 arerepositioned under the force of the elastic band 513 to an initial orhome position as illustrated in FIG. 5I. Referring to FIGS. 5F and 5G,passageway 520P for strip 74 is illustrated and is formed by the upperportion 502, sidewalls 503, 503A and the pivotal bottom plate or portion550.

FIGS. 6 through 11, and 14 through 19, illustrate various configurationsof the collated strip 62, 64, 88, 68, 70, and 72 of integrally connectedT-Nuts. All of these examples are made in accord with the teachings ofthe present invention. FIGS. 6, 6A, 6B and 6C are views 600, 600A, 600Band 600C, respectively, of another configuration of T-Nuts made inaccordance with the present invention. FIG. 6 illustrates a strip ofcollated T-Nuts 62 with an oblong-shaped flanged head with a frangibleconnection portion 48A. The oblong-shaped flanged head is provided withholes 63 which provide a secondary support means for affixation to asubstrate 89. Arrow 93A in FIG. 6 indicates the interconnection betweenadjacent T-Nuts. A frangible portion 48A in combination with carry tabs94A, 94B join adjacent T-Nuts together enabling further processing.Carry tabs 94A, 94B and frangible portion 48A are used to join theT-Nuts together and enable further processing of the T-Nuts andinstallation of the T-Nuts into a substrate. FIG. 6D is an enlargement600D of the frangible portion 48A which illustrates slot 90A in theupper portion of the frangible portion and vertical slots 91A, 91A onboth sides of the frangible portion.

FIGS. 7, 7A, 7B and 7C are views 700, 700A, 700B and 700C, respectively,of a further configuration or example of T-Nuts made in accordance withthe present invention with a frangible connection portion 48B. FIG. 7illustrates a further variation in the head shape that can be applied tothe strip 64 of collated T-Nuts and illustrates the provision of skives65 on the exterior of the cylindrical shapes which enable the T-Nut tobe more firmly attached to the substrate to which it is applied. Arrow93B in FIG. 7 indicates the interconnection between adjacent T-Nuts. Afrangible portion 48B in combination with carry tabs 95A, 95B joinadjacent T-Nuts together enabling further processing. Carry tabs 95A,95B and frangible portion 48B are used to join the T-Nuts together andenable further processing of the T-Nuts and installation of the T-Nutsinto a substrate. FIG. 7D is an enlargement 700D of the frangibleportion 48B which illustrates slot 90B in the upper portion of thefrangible portion 48B and vertical slots 91B, 91B on both sides of thefrangible portion.

FIGS. 8, 8A, 8B and 8C are views 800, 800A, 800B, 800C, respectively, ofa still further configuration or example of T-Nuts made in accordancewith the present invention with a frangible connection portion 48C. FIG.8 shows a strip 66 of T-Nuts with a variation in the flange design andwith attachment prongs 67 of different design than previouslyillustrated. Arrow 93C in FIG. 8 indicates the interconnection betweenadjacent T-Nuts. A frangible portion 48C in combination with carry tabs96A, 96B join adjacent T-Nuts together enabling further processing.Carry tabs 96A, 96B and frangible portion 48C are used to join adjacentT-Nuts together and enable further processing of the T-Nuts andinstallation of the T-Nuts into a substrate. FIG. 8D is an enlargement800D of the frangible portion 48C which illustrates the slot 90C in theupper portion of the frangible portion and vertical slots 91C, 91C onboth sides of the frangible portion.

FIGS. 9, 9A, 9B and 9C are views 900, 900A, 900B, 900C, respectively, ofyet another configuration or example of T-Nuts made in accordance withthe present invention with a frangible connection portion 48D. FIG. 9shows a strip of T-Nuts 68 with a still further flange head shape and aslightly different attachment prong 69 design. Arrow 93D in FIG. 9indicates the interconnection between adjacent T-Nuts. A frangibleportion 48D in combination with carry tabs 97A, 97B join adjacent T-Nutstogether enabling further processing. Carry tabs 97A, 97B and frangibleportion 48D are used to join adjacent T-Nuts together and enable furtherprocessing of the T-Nuts and installation of the T-Nuts into asubstrate. FIG. 9D is an enlargement 900D of the frangible portion 48Dwhich illustrates the slot 90D in the upper portion of the frangibleportion and vertical slots 91D, 91D on both sides of the frangibleportion.

FIGS. 10, 10A, 10B and 10C are views 1000, 1000A, 1000B, 1000C,respectively, of an additional configuration or example of T-Nuts madein accordance with the present invention with a frangible connectionportion 48E. FIG. 10 illustrates another flange shape for a strip 70 ofT-Nuts which have attachment prongs 71 similar to the ones previouslyshown. FIG. 10 also illustrates the variation in the frangible portion48E which is used to connect adjacent T-Nuts together. Arrow 93E in FIG.10 indicates the interconnection between adjacent T-Nuts. A frangibleportion 48E in combination with carry tabs 98A, 98B join adjacent T-Nutstogether enabling further processing. Carry tabs 98A, 98B and frangibleportion 48E are used to join adjacent T-Nuts together and enable furtherprocessing of the T-Nuts and installation of the T-Nuts into asubstrate. FIG. 10D is an enlargement 1000D of the frangible portion48E. FIG. 10D illustrates the slot 90E in the upper portion of thefrangible portion 48E and the vertical slots 91E, 91E on both sides ofthe frangible portion 48E.

FIGS. 11, 11A, 11B and 11C are views 1100, 1100A, 1100B, 1100C,respectively, of the final example of T-Nuts made in accordance with thepresent invention. FIG. 11 is a still further variation of a strip ofT-Nuts 72 which are connected together by metal rails 73 by leaving aportion of the first and second portions of the metal strip intact or inplace so that these thin or narrow portions are all that need be severedin putting the T-Nuts in place. Arrow 93F in FIG. 11 indicates theinterconnection between adjacent T-Nuts. A frangible portion 48F incombination with carry tab 99A, 99B join adjacent T-Nuts togetherenabling further processing. Carry tabs 99A, 99B and frangible portion48F are used to join adjacent T-Nuts together and enable furtherprocessing of the T-Nuts and installation of the T-Nuts into asubstrate. FIG. 11D is an enlargement 1100D of the frangible portions48F, 48F. FIG. 11 illustrates the slots 90F, 90F in the upper portion ofthe frangible portion 48E and the vertical slots 91F, 91F on both sidesof the frangible portion.

FIGS. 14, 14A, 14B,14C, 14D, 14E and 14F are views 1400, 1400A, 1400B,1400C, 1400D, 1400E, and 1400F, respectively, of a still furtherconfiguration or example of T-Nuts of the present invention with afrangible portion 148. The frangible portion 148 is a weakenedconnection which can be easily severed as illustrated in FIGS. 5D-5J.FIG. 14 shows a strip 74 of T-Nuts with a variation in the flange design150 and with attachment prongs 169A, 169B, 169C, 169D of differentdesign than previously illustrated. Arrow 93G in FIG. 14 indicates theinterconnection between adjacent T-Nuts. Carry tabs 194A, 194B include afrangible portion 148. The frangible portion 148 in combination withcarry tabs 194A, 194B join adjacent T-Nuts together enabling furtherprocessing. Carry tabs 194A, 194B and frangible portion 148 thereof areused to join adjacent T-Nuts together and enable further processing ofthe T-Nuts and installation of the T-Nuts into a substrate. Carry tabs194A, 194B include the portion of the flange 150 proximate the frangibleportion 148.

FIG. 14 is an isometric illustration 1400 of a length of the strip 74 ofanother example of collated T-Nuts slightly enlarged wherein the barrel142 has a first diameter having a first circumference 142T and a seconddiameter having a second circumference 142B. FIG. 14A is a slightlyenlarged top schematic view 1400A of the collated T-Nuts of FIG. 14illustrating the frangible connection 148 between adjacent T-Nuts. FIG.14B is a plan view 1400B of FIG. 14. Bores 152B through T-Nuts areillustrated well in FIGS. 14-14C. FIG. 14C is a cross-sectional view1400C of FIG. 14B taken along the lines 14C-14C illustrating interiorthreads 1421 in the first diameter having a first circumference 142T.FIG. 14D is an end view 1400D of FIG. 14B taken along the lines 14D-14D.

FIG. 14E is a plan view 1400E similar to FIG. 14B with a frangibleconnection 148Z having a slight underside 48Z indentation. FIG. 14F isan enlargement 1400E of a portion of FIG. 14E illustrating frangibleconnection 148Z having a slight indentation 48Z. The indentation 48Z issometimes a consequence of manufacturing the characteristics of theflange

FIGS. 15, 15A, 15B, 15C, and 15D are views 1500, 1500A, 1500B, 1500C,and 1500D respectively, of a configuration or example of T-Nuts similarto those illustrated in FIG. 14. FIG. 15 is an isometric illustration1500 of a length of the strip 74 of another example of collated T-Nutsslightly enlarged wherein the barrel 142 has a first diameter having afirst circumference 142T and a second diameter having a secondcircumference 142B similar to FIG. 14, except with interior threads 1431completely through the barrel 142. FIG. 15A is a slightly enlarged topschematic view 1500A of the collated T-Nuts of FIG. 15 illustrating thefrangible connection 148 between adjacent T-Nuts. The frangibleconnection is a weakened portion which may be severed as illustrated inFIGS. 5D-5J. FIG. 15B is a plan view 1500B of FIG. 15. FIG. 15C is across-sectional view 1500C of FIG. 15B taken along the lines 15C-15Cillustrating a fully threaded 1431 barrel 142. Bore 152B is illustratedwell in FIGS. 15, 15A and 15C. FIG. 15D is an end view 1500D of FIG. 15Btaken along the lines 15D-15D.

FIGS. 16, 16A, 16B,16C, and 16D are views 1600, 1600A, 1600B, 1600C, and1600D respectively, of a configuration or example of T-Nuts similar tothose illustrated in FIG. 14. FIG. 16 is an isometric illustration 1600of a length of the strip 74 of another example of collated T-Nutsslightly enlarged wherein the barrel 142 has a first diameter having afirst circumference 142T and a second diameter having a secondcircumference 142B similar to FIG. 14, except with interior threads 1441residing in the portion of the barrel 142 having a second diameterhaving a second circumference 142B. FIG. 16A is a slightly enlarged topschematic view 1600A of the collated T-Nuts of FIG. 16 illustrating thefrangible connection 148 between adjacent T-Nuts. The frangibleconnection or portion 148 is a weakened portion which may be easilysevered as illustrated in FIGS. 5D-5J. FIG. 16B is a plan view 1600B ofFIG. 16. FIG. 16C is a cross-sectional view 1600C of FIG. 16B takenalong the lines 16C-16C illustrating interior threads 1441 in the seconddiameter having a second circumference 142B. FIG. 16D is an end view1600D of FIG. 16B taken along the lines 16D-16D.

FIGS. 17, 17A, 17, 17C, and 17D are views 1700, 1700A, 1700B, 1700C, and1700D, respectively, of a still further configuration or example ofT-Nuts made in accordance with the present invention with a frangibleportion 148. FIG. 17 shows a strip 76 of T-Nuts with a flange design 150and with attachment prongs 169A, 169B, 169C, 169D of identical to thoseillustrated in FIG. 14. Arrow 93G in FIG. 17 indicates theinterconnection between adjacent T-Nuts. Carry tabs 194A, 194B include afrangible portion 148. The frangible portion is a weakened portion whichmay be severed as illustrated in FIGS. 5D-5J. The frangible portion 148in combination with carry tabs 194A, 194B join adjacent T-Nuts togetherenabling further processing. Carry tabs 194A, 194B and frangible portion148 thereof are used to join adjacent T-Nuts together and enable furtherprocessing of the T-Nuts and installation of the T-Nuts into asubstrate. Carry tabs 194A, 194B include the portion of the flange 150proximate the frangible portion 148.

FIG. 17 is an isometric illustration 1700 of a length of the strip 76 ofanother example of collated T-Nuts slightly enlarged wherein the barrel142 is cylindrically shaped 142S with interior threads 1451 in the upperportion of the bore 148B of the cylindrically shaped barrel 142S. FIG.17A is a slightly enlarged top schematic view 1700A of the collatedT-Nuts of FIG. 17 illustrating the frangible connection 148 betweenadjacent T-Nuts. FIG. 17B is a plan view 1700B of FIG. 17. FIG. 17C is across-sectional view 1700C of FIG. 17B taken along the lines 17C-17Cillustrating interior threads 1451 in the upper portion of the bore148B. FIG. 17D is an end view 1700D of FIG. 17B taken along the lines17D-17D.

FIG. 18 is an isometric illustration 1800 of a length of the strip 76 ofanother example of collated T-Nuts slightly enlarged wherein the barrel142 is cylindrically shaped 142S similar to FIG. 17, except withinterior threads 146I completely through the bore 148B of thecylindrically shaped 142S barrel 148B. FIG. 18A is a slightly enlargedtop schematic view 1800A of the collated T-Nuts of FIG. 18 illustratingthe frangible connection 148 between adjacent T-Nuts. The frangibleportion or connection 148 is easily severed as illustrated in FIGS.5D-5J. FIG. 18B is a plan view 1800B of FIG. 18. FIG. 18C is across-sectional view 1800C of FIG. 18B taken along the lines 18C-18Cillustrating interior threads 146 i through the entire bore 148 b of thecylindrically shaped 142S barrel 142. FIG. 18D is an end view 1800D ofFIG. 18B taken along the lines 18D-18D.

FIG. 19 is an isometric illustration 1900 of a length of the strip 76 ofanother example of collated T-Nuts slightly enlarged wherein the barrel142 is cylindrically shaped 142S with interior threads 1471 in the lowerportion of the bore of the cylindrically shaped 142S barrel 142. FIG.19A is a slightly enlarged top schematic view 1900A of the strip 76 ofcollated T-Nuts of FIG. 19 illustrating the frangible connection 148between adjacent T-Nuts. FIG. 19B is a plan view 1900B of FIG. 19. FIG.19C is a cross-sectional view 1900C of FIG. 19B taken along the lines19C-19C illustrating interior threads in the lower portion of the bore.FIG. 19D is an end view 1900D of FIG. 19B taken along the lines 19D-19D.

FIG. 12 is a block diagram 1200 of processing stations used to make thecomplete and finished metal strips 33, 62, 64, 66, 68. 70 and 72. Thecontinuous metal strip dispensing station 1201 dispenses rolled steel orstainless steel which is dispensed to a slack control station 1202. Theslack control station can be a weight which is slidably suspended fromthe unrolled steel intermediate the rolled/coiled station and the firstprogressive die of several progressive dies which form the barrel of theT-Nut successively longer and diametrically larger as the metal stripprogresses through the dies. The progressive dies are describedhereinabove. After the continuous metal strip has progressed through thelast die forming station, a tapping/threading station 1204 formsinterior threads in the barrel of the T-Nut. Alternatively, a step offorming a counterbore 1203A may be employed before tapping threads inthe inner bore of the T-Nuts. Still alternatively, a stepped exterior1203B may be formed before tapping threads in the inner bore of theT-Nuts. The remainder of the metal strip is then characterized after itleaves the tapping/threading station by a die cutting station 1205 whichforms a frangible portion and/or forms specific configurations of theT-Nuts such as prongs, holes, welding bosses, slots and rails.

By specific configurations, it is meant the configuration as set forthin any of FIGS. 4, 6, 7, 8, 9, 10, 11, 14, 15, 16, 17, 18 and 19. FIG.4A illustrates one example of the frangible portion 48 intermediateadjacent T-Nuts. The frangible portion 48 includes a slot or slit in thetop portion 15 thereof. A feed mechanism 1206 includes the spring loadedadvancement finger which positions the continuous metal strip of T-Nutsvertically and horizontally as desired. From the feed mechanism, theT-Nuts can be either cut using a cutting mechanism 1207 or a cutting andinserting mechanism 1208.

REFERENCE NUMERALS

-   100, 100A, 100B—illustrates a die press at a first die station in    three successive positions in operating on a strip of metal in    performing the method of the present invention.-   100C—isometric illustration of the end of the strip of metal as it    leaves the press illustrated in FIG. 1B.-   100D—illustrates a die press at a second die station as operating on    the strip of metal after it has left the position of FIG. 1B in the    condition of FIG. 1C.-   100E—isometric illustration of the end of the strip of metal as    operated on in the press of FIG. 1D.-   100E—illustrates a die press at a third die station as operating on    the strip of metal after it has left the position of FIG. 1D in the    condition of FIG. 1E.-   100G—isometric illustration of the end of the strip of metal as    operated on in the press of FIG. 1F.-   100H—illustrates a die press at a fourth die station as operating on    the strip of metal after it has left the position of FIG. 1F in the    condition of FIG. 1G.-   100I—isometric illustration of the end of the strip of metal as    operated on in the press of FIG. 1H.-   10—strip of deformable metal material-   12—first side portion of 10-   13—second side portion of 10-   15—top portion of 10-   16—bottom portion of 10-   18—first die station-   18A—die members of 18-   19—second die station-   19A—die members at 19-   20—third die station-   20A—die members at 20 (FIG. 1F)-   21—fourth die station-   21A—die members at 21 (FIG. 1H)-   22—cylindrical shape at 18 (FIG. 1B)-   22A—cylindrical shape at 19 (FIG. 1D)-   22B—cylindrical shape at 20 (FIG. 1F)-   22C—cylindrical shape at 21 (FIG. 1H)-   24—fifth die station-   25—sixth die station-   25A—die-   28—taps-   33—strip of finished and completed T-Nuts ready for use/insertion-   34—press-   35—upper platform-   36—lower platform-   37—spring-   38—spring-   39—upper run-   40—lower run-   42—cylinder-   44—threads-   46—attachment prongs-   48, 48A, 48B, 48C, 48D, 48E, 48F—frangible portions of strip between    carry tabs of adjacent T-Nuts-   50—flange-   52—shearing station-   53—positioning abutment-   54—advancement finger-   55—shearing blade assembly-   56—blade-   57—guide cylinder-   58—springs-   59—shearing ram-   60—guide finger-   61, 61A—openings in the substrate-   62, 64, 66, 68, 70, 72, 74, 76—strips of finished and completed    collated T-Nuts ready for use/insertion-   63—holes in flanges-   65—skives-   67, 69, 71—prongs-   73—rails-   74E—endmost T-Nut of collated T-Nut strip 74, FIG. 14, FIGS. 5F and    5G-   81—arrow indicating movement into engagement with positioning    abutment-   82—arrow indicating upward movement of continuous strip of T-Nuts-   83—arrow indicating movement of substrate 89 leftwardly-   89—substrate-   90—top slot or slit of frangible portion 48, FIG. 4E-   90A—top slot or slit of frangible portion 48A, FIG. 6D-   90B—top slot or slit of frangible portion 48B, FIG. 7D-   90C—top slot or slit of frangible portion 48C, FIG. 8D-   90D—top slot or slit of frangible portion 48D, FIG. 9D-   90E—top slot or slit of frangible portion 48E, FIG. 10D-   90E—top slot or slit of frangible portion 48F of FIG. 11D-   91—vertical slot or slit of frangible portion 48, FIG. 4E-   91A—vertical slot or slit of frangible portion 48A, FIG. 6D-   91B—vertical slot or slit of frangible portion 48B, FIG. 7D-   91C—vertical slot or slit of frangible portion 48C, FIG. 8D-   91D—vertical slot or slit of frangible portion 48D, FIG. 9D-   91E—vertical slot or slit of frangible portion 48E, FIG. 10D-   91F—vertical slot or slit of frangible portion 48F, FIG. 11D-   92A, 92B—carry tabs joined together by frangible portion 48, FIG. 4-   93—arrow indicating carry tabs 92A, 92B, FIG. 4-   93A—arrow indicating carry tabs 94A, 94B, FIG. 6-   93B—arrow indicating carry tabs 95A, 95B, FIG. 7-   93C—arrow indicating carry tabs 96A, 96B, FIG. 8-   93D—arrow indicating carry tabs 97A, 97B, FIG. 9-   93E—arrow indicating carry tabs 98A, 98B, FIG. 10-   93F—arrow indicating carry tabs 99A, 99B, FIG. 11-   93G—arrow indicating carry tabs 194A, 194B-   94A, 94B—carry tabs joined by frangible portion 48A, FIG. 6-   95A, 95B—carry tabs joined by frangible portion 48B, FIG. 7-   96A, 96B—carry tabs joined by frangible portion 48C, FIG. 8-   97A, 97B—carry tabs joined by frangible portion 48D, FIG. 9-   98A, 98B—carry tabs joined by frangible portion 48E, FIG. 10-   99A, 99B—carry tabs joined by frangible portion 48F, FIG. 11-   142—barrel of T-Nut-   142B—bottom of barrel-   142S—cylindrical barrel, FIGS. 17-19-   142T—top of barrel-   142I—threads in first end 142T of bore 152B, FIG. 14-   143I—threads in second end 142B of bore 152B, FIG. 15-   144I—threads in second end 142B of bore 152B, FIG. 16-   145I—threads in upper portion of bore 148B-   146I—threads completely through bore 148B-   147I—threads in lower portion of bore 148B-   148—frangible connection, FIGS. 14 through 19-   148B—bore in T-Nut, FIGS. 17-19-   152B—bore in T-Nut, FIGS. 14-16-   169A, 169B, 169C, 169D—prongs (pawls), FIGS. 14-19-   194A, 194B—carry tabs joined by frangible portion 48G, FIGS. 14, 15    and 16-   200, 200A, 200B—illustrate a fifth die station at which the    cylindrical members produced at the previous stations are tapped and    provided with threads.-   200C—an isometric illustration of the end of the strip of metal as    operated on at the fifth die station of FIG. 2B.-   300, 300A, 300B—illustrates a sixth station at which the strip of    metal between the formed cylindrical members is die cut to produce    the heads on the T-Nuts and produce various flange features such as    attachment prongs as shown in FIG. 3B.-   300C—an isometric illustration of the end of the strip of metal as    operated on at the sixth die station of FIG. 3B.-   400—an isometric illustration similar to FIG. 3B showing a slightly    longer length of the connected and formed T-Nuts and slightly    enlarged for detail.-   400A—an enlarged portion of FIG. 4 illustrating the connection    between adjacent T-Nuts and the location at which they will be    severed at about their ultimate location of use.-   400B—a plan view of FIG. 4.-   400C—an elevational view of FIG. 4B.-   400D—an end view of FIG. 4C.-   500—a view illustrating the length of integrally connected T-Nuts as    shown in FIGS. 4 through 4D as wound into a helical configuration    for ease in shipping and/or manufacturing.-   500A—a view of the T-Nuts shown in FIG. 5 in connection with    apparatus to sever the endmost T-Nut from its strip and in position    to be installed in a substrate.-   500B—a view of the apparatus of FIG. 5A severing the endmost T-Nut    from its strip and placing it in an aperture in a substrate.-   500C—a view of the apparatus of FIG. 5B moved back in position to    install another T-Nut from the end of the strip into another    aperture in a substrate.-   500D—a schematic side view of a strip of collated T-Nuts in    combination with another example of an apparatus (an escapement) to    sever the endmost T-Nut from its strip.-   500E—a schematic top view of a strip of collated T-Nuts in    combination with another example of an apparatus (an escapement) to    sever the endmost T-Nut from its strip.-   500F—a schematic cross-sectional view of a strip of collated T-Nuts    in combination with another example of an apparatus (an escapement)    to sever the endmost T-Nut from its strip taken along the lines    5F-5F of FIG. 5D illustrating the piston and the tool for advancing    the strip, and, illustrating the endmost T-Nut in the chamber for    separation from the strip.-   500G—a schematic cross-sectional view of a strip of collated T-Nuts    in combination with another example of an apparatus (an escapement)    to sever the endmost T-Nut from its strip taken along the lines of    5G-5G of FIG. 5E illustrating the endmost T-Nut in the chamber for    separation from the strip and the shearing inbody and guide aligned    with the endmost T-Nut.-   500H—a schematic cross-sectional view of a strip of collated T-Nuts    in combination with another example of an apparatus (an escapement)    to sever the endmost T-Nut from its strip illustrating the hinged    bottom plate of the escapement rotated downwardly enabling the    frangible connection of the endmost T-Nut in the chamber for    separation from the strip.-   500I—a schematic cross-sectional view of a strip of collated T-Nuts    in combination with another example of an apparatus (an escapement)    to sever the endmost T-Nut from its strip illustrating the hinged    bottom plate of the escapement returned to its home position    supporting the strip of collated T-Nuts.-   500J—a schematic cross-sectional view of a strip of collated T-Nuts    in combination with another example of an apparatus (an escapement)    to sever the endmost T-Nut from its strip illustrating the shearing    inbody pushing and inserting the endmost T-Nut into a substrate.-   501—shearing ram inbody which shears the endmost T-nut from the    strip of integrally connected T-Nuts-   501G—guide of inbody 501-   502—upper portion of the escapement 599-   502N—nut of stud holding upper portion of the escapement to side    walls 503-   503, 503A—side wall of escapement 599-   504, 504A—nut of pivot 504P-   504P—pivot of hinged bottom 550 of escapement 599-   505—upper pin for elastic band 513-   506—lower pin located lower portion 507 of the hinged bottom 550 for    elastic band-   507—lower portion of the hinged bottom 550-   508—cutting blade-   508C—cutting surface of cutting blade 508-   509—bolt for affixing the cutting blade to plate 510 of the    escapement-   510—plate of the escapement/cutting chamber-   511, 511A—plate of the escapement/cutting chamber-   512—plate of the escapement/cutting chamber-   513—elastic band-   520P—passageway for strip 74 within escapement 599-   530—double acting piston-   530N—pivot nut for piston 530-   530T—gripping tool advancing strip 74 of T-Nuts-   530P, 530Q—pneumatic connections to cylinder 530-   530R—rod of tool 530T which engages side wall 503-   531—open slot in side wall 503 for permitting access of gripping    tool 530T to pawls of T-Nuts on strip 74-   531S—guiding surface gripping tool 530T of side wall 503-   532—open slot in side wall 503A for permitting access of gripping    tool 530T to pawls of T-Nuts on strip 74-   540, 541—surfaces on T-Nut engaged by surfaces 540R, 541R of    gripping tool 530T-   540R, 541R—gripping surfaces of tool 530T-   550—hinged bottom of escapement-   558—opening in substrate 560-   560—substrate 558-   597—core of coil, FIG. 5K-   598—rolled coil of strip 74 of T-Nuts, FIG. 5K-   599—escapement-   600, 600A, 600B, 600C, 600D—another configuration/example of a strip    of T-Nuts-   700, 700A, 700B, 700C, 700D—views of a further configuration/example    of a strip of T-Nuts-   800, 800A, 800B, 800C, 800D—views of a still further    configuration/example of a strip of T-Nuts-   900, 900A, 900B, 900C, 900D—views of yet another    configuration/example of a strip of T-Nuts-   1000, 1000A, 1000B, 1000C, 1000D—views of an additional    configuration/example of a strip of T-Nuts-   1100, 1100A, 1100B, 1100C, 1100D—views of another example of a strip    of T-Nuts.-   1200—block diagram of processing stations-   1201—metal strip dispensing station-   1202—slack control station-   1203—progressive dies forming barrel successively longer and    diametrically larger-   1203A—forming counterbore-   1203B—forming stepped exterior 1203B-   1204—tapping/threading station-   1205—die cutting station forming frangible portion and/or forming    specific configuration of prongs, holes and rails-   1206—feeding mechanism-   1207—cutting mechanism-   1208—cutting and inserting mechanism-   1300—prior art backing strip 1201 securing individual T-Nuts 1202    thereto by means of adhesive 1300A—a prior art device illustrated in    U.S. Pat. No. 5,214,843 with wires 1304, 1305 welded to individual    T-Nuts 1302.-   1301—backing strip-   1302—T-Nut-   1304, 1305—wires-   1400, 1400A, 1400B, 1400C, 1400D, 1400E—views of another example of    a strip T-Nuts of having a stepped exterior diameters with a    partially threaded bore at a first end portion of each of the T-Nuts-   1500, 1500A, 1500B, 1500C, 1500D—views of another example of a strip    of T-Nuts having a stepped exterior diameters with a fully threaded    bore-   1600, 1600A, 1600B, 1600C, 1600D—views of another example of a strip    of T-Nuts having a stepped exterior diameters with a partially    threaded bore at a second end portion of each of the T-Nuts-   1700, 1700A, 1700B, 1700C, 1700D—views of another example of a strip    of T-Nuts having a cylindrical barrel with a partially threaded bore    in an upper portion of each of the T-Nuts-   1800, 1800A, 1800B, 1800C, 1800D—views of another example of a strip    of T-Nuts having a cylindrical barrel with a fully threaded bore-   1900, 1900A, 1900B, 1900C, 1900D-1700D—views of another example of a    strip of T-Nuts having a cylindrical barrel with a partially    threaded bore in an lower portion of each of the T-Nuts-   F—force applied by a spring to tension piston 530 and gripping tool    530T

The invention has been set forth by way of example only and thoseskilled in the art will readily recognize that changes to the examplesmay be made without departing from the spirit and the scope of theappended claims.

We claim:
 1. The method of making T-Nuts from a continuous length ofdeformable metal material, comprising the steps of: selecting acontinuous length of deformable metal material which is generally flatin configuration and which has first and second side portions and topand bottom portions; dispensing, using a dispensing station, saidselected length of deformable metal material, said deformable metalmaterial is rolled steel or stainless steel, to a slack control station;introducing said deformable metal material progressively into successivedie stations successively forming said T-Nuts; forming, using a diestation, spaced and generally hollow cylindrical configurations having adiameter and axial length on a metal surface of said deformable metalmaterial; repeating said step of forming, using a successive diestation, spaced and generally hollow cylindrical configurations having agreater diameter and greater axial length on said metal surfaces of saiddeformable metal material; moving said generally hollow cylindricalconfigurations to another station whereat a counterbore is formed ininterior portions of said generally hollow cylindrical configurationsand then interior threads are tapped/threaded on said interior portionsof said generally hollow cylindrical configurations; moving saidthreaded generally cylindrical configurations progressively to a stillfurther station wherein heads are formed for said T-Nuts in the natureof flanges which define a perimeter of said heads; forming centrallylocated carry tabs, said centrally located carry tabs include frangibleconnections between adjacent T-Nuts for ease in separation of saidT-Nuts, each of said frangible connections of said carry tabs include aslit therein, and, said centrally located carry tabs affix said adjacentT-Nuts together; feeding, using a feeding mechanism, said feedingmechanism includes a spring loaded advancement finger which positionssaid T-Nuts vertically and horizontally, to a cutting mechanism; and,separating and cutting said T-Nuts fed from said feed mechanism.
 2. Themethod of making T-Nuts from a continuous length of deformable metalmaterial, as claimed in claim 1, further comprising the steps of:forming a stepped exterior before tapping threads in a barrel portion ofsaid T-Nuts.
 3. The method of making T-Nuts from a continuous length ofdeformable metal material, as claimed in claim 1, further comprising thestep of: after the step of forming centrally located carry tabs,arranging said T-Nuts into a tight helical configuration for subsequentfeeding.
 4. The method of making T-Nuts from a continuous length ofdeformable metal material, as claimed in claim 1, further comprising thestep of: after forming said centrally located carry tabs, forming afirst and second pawl extending from said flange of each said T-Nutforming a first pair of pawls; after forming said centrally locatedcarry tabs, forming a third and fourth pawl extending from said flangeof each of said T-Nut forming a second pair of pawls; said first andsecond pairs of pawls oriented opposite each other; and, said carry tabsoriented opposite each other and at 90° with respect to said first andsecond pairs of pawls.
 5. The method of making T-Nuts from a continuouslength of deformable metal material, as claimed in claim 1, wherein eachof said frangible connections is rectangular in cross-section.
 6. Themethod of making T-Nuts from a continuous length of deformable metalmaterial, as claimed in claim 5, wherein each of said frangibleconnections is a weakened portion.
 7. The method of making T-Nuts from acontinuous length of deformable metal material, as claimed in claim 1,wherein each of said frangible connections is a weakened portion.
 8. Themethod of making T-Nuts from a continuous length of deformable metalmaterial, comprising the steps of: selecting a continuous length ofdeformable metal material which is generally flat in configuration andwhich has first and second side portions and top and bottom portions;dispensing, using a dispensing station, said selected length ofdeformable metal material, said deformable metal material is rolledsteel or stainless steel, to a slack control station; introducing saiddeformable metal material progressively into successive die stationswhich act to successively form spaced and generally hollow cylindricalconfigurations on said metal surface of said metal material ofsuccessively greater diameter and axial length; moving said generallyhollow cylindrical configurations successively to another stationwhereat threads are formed on interior portions of said generally hollowcylindrical configurations; moving said threaded generally cylindricalconfigurations progressively to a still further station wherein railsare formed and wherein heads are formed for said T-Nuts in the nature offlanges which define a perimeter of said heads; forming a first andsecond pawl extending from said flange of each said T-Nut forming afirst pair of pawls; forming a third and fourth pawl extending from saidflange of each said T-Nut forming a second pawls; forming carry tabs,said carry tabs include frangible connections between said first pair ofpawls of one T-Nut and said second pair of pawls of an adjacent T-Nutand said carry tabs include frangible connections between said flangesand said rails, each of said frangible connections of said carry tabsinclude a slit therein; feeding, using a feeding mechanism whichpositions said T-Nuts vertically and horizontally, to a cuttingmechanism; and, separating and cutting said T-Nuts from said feedmechanism.
 9. The method of making T-Nuts from a continuous length ofdeformable metal material as claimed in claim 8 wherein said threadsextend completely through said interior portions of said generallyhollow cylindrical configuration.
 10. The method of making T-Nuts from acontinuous length of deformable metal material as claimed in claim 8wherein said threads extend partially through said interior portions ofsaid generally hollow cylindrical configuration.
 11. The method ofmaking T-Nuts from a continuous length of deformable metal material,comprising the steps of: selecting a continuous length of deformablemetal material which is generally flat in configuration and which hasfirst and second side portions and top and bottom portions; dispensing,using a dispensing station, said selected length of deformable metalmaterial, said deformable metal material is rolled steel or stainlesssteel, to a slack control station; introducing said deformable metalmaterial progressively into successive die stations which act tosuccessively form spaced and generally hollow cylindrical configurationson said metal surface of said metal material of successively greaterdiameter and axial length, each of said generally hollow cylindricalconfigurations includes a bore therethrough, and said generally hollowcylindrical formations of said T-Nuts defining barrels; moving saidthreaded generally hollow cylindrical configurations progressively to astill further station wherein heads are formed for said T-Nuts in thenature of flanges which define a perimeter of said heads; formingcentrally located carry tabs, said centrally located carry tabs includefrangible connections between adjacent T-Nuts for ease in separation ofsaid T-Nuts, each of said frangible connections of said carry tabsinclude a slit therein, and, said centrally located carry tabs affixsaid adjacent T-Nuts together; moving said generally cylindricalconfigurations to another station whereat a counterbore is formed in thebore of the T-Nuts and then interior threads are tapped/threaded in saidbores therethrough; feeding, using a feeding mechanism, said feedingmechanism includes a spring loaded advancement finger which positionssaid T-Nuts vertically and horizontally, to a cutting mechanism; and,separating and cutting said T-Nuts from said feed mechanism.
 12. Themethod of making T-Nuts from a continuous length of deformable metalmaterial, as claimed in claim 11, further comprising the steps of:forming a stepped exterior before tapping threads in said bores of saidT-Nuts.
 13. The method of making T-Nuts from a continuous length ofdeformable metal material, as claimed in claim 11, further comprisingthe step of: after the step of forming centrally located carry tabs,arranging said T-Nuts into a tight helical configuration for subsequentfeeding.
 14. The method of making T-Nuts from a continuous length ofdeformable metal material, as claimed in claim 11, further comprisingthe step of: after forming said centrally located carry tabs, forming afirst and second pawl extending from said flange of each said T-Nutforming a first pair of pawls; after forming said centrally locatedcarry tabs, forming a third and fourth pawl extending from said flangeof each of said T-Nut forming a second pair of pawls; said first andsecond pairs of pawls oriented opposite each other; and, said carry tabsoriented opposite each other and at 90° with respect to said first andsecond pairs of pawls.
 15. The method of making T-Nuts from a continuouslength of deformable metal material, as claimed in claim 11, whereineach of said frangible connections is rectangular in cross-section.